Determination of the optimum tool geometry of a cutting insert by finite element simulation of compaction and sintering

Designing, manufacturing and commissioning of the tooling often determines the delivery time of a new powder-metallurgical component. To speed-up this process, computer simulations of die compaction and sintering assist in the development stage. Today, finite element simulations of the compaction process in combination with appropriate material laws for the powder allow quantitative predictions of the density distribution in the green body as well as the tool loadings. The shape after firing can be predicted by using an appropriate material law for sintering. The sinter distortions are a result of inhomogeneous density distributions in the green body. These distortions can be minimized by optimum press kinematics, and the remainder can be compensated by appropriately shaped punch surfaces.